In the industrial application of multi-laser metal additive manufacturing equipment, the traditional multi-laser calibration model has long been constrained by multiple core pain points, becoming a key bottleneck that restricts users from improving production efficiency, ensuring product quality, and optimizing cost structures:
On one hand, traditional calibration heavily relies on manual experience, with complex processes and low standards. For example, in the case of a 1.5-meter large-format 3D printing device, the calibration cycle typically requires 2 people 3-5 days, making it more susceptible to calibration accuracy instability due to operational differences among personnel. It is difficult to achieve full-format printing consistency on large-format equipment;
On the other hand, traditional calibration requires frequent opening of the chamber for debugging, which disrupts chamber pressure and disturbs powder spreading, leading to powder oxidation and forming defects during production. It also requires specialized tooling and consumables. For instance, in the case of titanium alloy printing on a 1.5-meter large-format 3D printing device, the comprehensive cost for repeated printing tests of sample blocks alone can reach nearly 30,000 yuan, further increasing operational burdens when combined with labor and maintenance costs.
Huashu High-Tech’s independently developed automatic stitch calibration technology is an innovative technology based on high signal-to-noise ratio signal processing technology and self-developed algorithms. It breaks through the efficiency bottleneck, high costs, and quality fluctuations of the traditional galvanometer stitch calibration model with a “one-click automatic” solution, bringing comprehensive improvements in efficiency, precision, and cost control to industrial users.
Following its successful application on the FS350M-4 device, Huashu High-Tech’s automatic stitch calibration technology has been implemented on the FS1521M-U-32 laser metal large-format 3D printing equipment with a forming size of 1510×1510×1650mm, and has been installed on multiple client machines, enhancing productivity in the high-end manufacturing sector.
01Increase Efficiency: 32 Laser 4-Hour Stitch Calibration
The multi-laser stitch calibration technology equipped on the FS1521M-U-32 completely eliminates reliance on manual experience, achieving “in-situ stitch calibration” through dedicated Huashu software, compressing the time for 32 laser stitch calibration to under 4 hours, compared to the traditional manual calibration or inefficient automation solutions that take 2 people 3-5 days, resulting in an efficiency increase of over 18 times.
02High Precision: 32 Laser Calibration Precision < 50μm
The FS1521M-U-32 metal large-format 3D printing equipment has a total of 32,232 calibration points across the entire area, with calibration precision 100% better than 50μm, achieving consistent precision control from individual laser spots to the global printing area, ensuring stable product quality.
03Maintain Stability: Consistency Between Debugging and Production Environments
Compared to other calibration technologies, Huashu High-Tech’s automatic stitch calibration technology can achieve “one-click automatic debugging without opening the chamber”, ensuring that “the debugging environment is completely consistent with the production environment” —
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Consistency of the scraper powder surface: ensuring that the calibration plane completely overlaps with the powder spreading plane;
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Consistency of chamber pressure: Calibration after inflation, ensuring that the key optical structure calibration process is consistent with the printing process;
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Consistency of substrate temperature: Ensuring thermal radiation of the substrate and thermal balance within the chamber, with the calibration process consistent with the printing process.
This means that the working conditions simulated during the debugging process are exactly the same as those during actual production, avoiding production issues caused by environmental differences, reducing uncertainty in the production process, and enhancing reliability and stability, allowing customers to feel more secure during production.
04Reduce Costs: No Additional Tooling or Consumables Required
The customer costs in additive manufacturing encompass not only visible expenditures such as equipment procurement and consumable consumption but also involve hidden costs such as time and labor. The automatic stitch calibration technology of the FS1521M-U-32 does not require additional consumable preparations, reducing costs for customers from both visible and hidden aspects —
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Visible costs: For example, in titanium alloy printing, there is no need to print sample blocks for verification after calibration, allowing for direct production. Under certain typical conditions, each calibration can save about 30,000 yuan in comprehensive costs; the design without tooling and consumables significantly reduces the cost of each production batch;
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Hidden costs: Automatic stitch calibration replaces manual debugging, reducing repetitive labor for technicians, saving labor costs; “one-click debugging without opening the chamber” can avoid chamber contamination, extend equipment maintenance cycles, and reduce operational costs.
Huashu High-Tech’s automatic stitch calibration technology successfully applied on the FS1521M-U-32 laser metal large-format 3D printing equipment brings users advantages such as improved production efficiency, reduced costs, guaranteed precision, and enhanced production stability.
In the future, Huashu High-Tech will continue to focus on technological innovation as the core driving force, deepening the iterative upgrade of automatic stitch calibration technology. It plans to expand this technology to more models in its product line and optimize customized solutions in conjunction with the personalized needs of high-end manufacturing fields such as aerospace, automotive, molds, and medical.
Previous Reviews
Huashu High-Tech releases automatic stitch calibration technology, achieving multi-laser stitch calibration with “one-click automatic”
Huashu High-Tech FS1521M Series: 16/32 Laser Efficient Collaboration, Empowering Efficient Batch Manufacturing of Ultra-Large Precision Parts
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